Nice engineery geakness Hern, thats awesome.
Regardless of buns of steel,.... or CoCr,... or what have you, I really wonder if the 50 to 100 um (I think) of spacing is the biggest issue. If it is, then one would suspect, as Dave points out, that the tighter the muscles around the hip, the less ability for the prosthetic compounds to vibrate against each other. If that is indeed what Jason is experiencing. Picture a BHR out of the wrapper in the docs office, if you put one rubber band around the 2 components, then put the thing on top of a running washer machine, and see how clangy it is. Then put 3 or 5 rubber bands around the components and do the same. I would think you would have a lot less clanginess with the more rubber bands. At a macroscopic level we assume the distance between the 2 is not much, we visualize them touching each other. Although at a microscopic level, they don't really touch and syn fluid is all that separates them, so strong vibrations seem like they could easilly cause discomfort in a hip that has less tight muscles.
What about harmonic oscillations? Maybe there is some amount of harmonics going on, due to the component shape and material, and the motor frequency/RPM, it could then be additive.